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Process Control Systems

The document provides an overview of topics covered in an Industrial Electronics course. It discusses continuous, batch, and individual processes as well as centralized and distributed control systems. Open-loop and closed-loop control systems are described along with the components of closed-loop systems including set point, process variable, error amplifier, controller, and output actuator. A container filling process is used as an example of closed-loop control. Regulators and process control variables are also mentioned. Finally, different industrial process control modes are listed including two-position, proportional, integral, differential, PI, PD, and PID control.

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Hammad Ansari
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© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
132 views

Process Control Systems

The document provides an overview of topics covered in an Industrial Electronics course. It discusses continuous, batch, and individual processes as well as centralized and distributed control systems. Open-loop and closed-loop control systems are described along with the components of closed-loop systems including set point, process variable, error amplifier, controller, and output actuator. A container filling process is used as an example of closed-loop control. Regulators and process control variables are also mentioned. Finally, different industrial process control modes are listed including two-position, proportional, integral, differential, PI, PD, and PID control.

Uploaded by

Hammad Ansari
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
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Review of Last class class..

Industrial Electronics (3+0)


Week-02 23rd Sep 2012

Industrial Electronics Intro Course Intro Introduction to Process Control Systems Types of processes

Continous Batch Individual process Individual control Centralized control Distributed control
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Process control configurations


Process Control Systems

Week-01
Instructor: Engr. Shiraz Latif

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Structure of process control systems Introduction to PLC & Ladder logic

Open-loop v/s closed-loop systems

Open-loop p p control system y

Process is controlled by inputting to the controller the desired set point (command signal or reference f signal) i l) Accepting whatever the final results Only input is the desired set level hence blind control No information regarding current status Inexpensive and less complex Less accurate Poor process control

Open loop speed control Of DC motor

Closed-loop p control system y


Components p of closed-loop p control

Output of a process affects the input Current output is measured and compared to the desired output

Set point

Error signal = desired output actual output

Continuous adjustments until error becomes zero (ideally)

Input that determines the desired operating point for the process th Usually provided by the operator, or may be provided by some system Variable that is being measured and controlled Contains information about the process current status Feedback signal Ideally matches the set pint Ideally,
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Process variable

. Components p

Error Amplifier

Container Filling Closed-loop process control

Determines whether the process operation matches th set the t point i t Differential amplifier Magnitude and polarity of error signaldetermines how the process be brought back under control Produces corrective output signal based on error signal Component C t that th t di directly tl affects ff t a process change h Eg. Motors, heaters, fans, solenoids

Controller

Output actuator

Container filling g process p control explanation.. p

Regulators:

How the process works?

Identify y inputs p and outputs.. p Identify


Set p point ? Process variable? Error amplifier? Controller? Output actuator?


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A closed-loop system that maintains a steady level or value of some quantity Used in industrial processes to provide precise regulation p g of some parameter p like voltage, speed, current, tension, position, temperature

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Process Control variables

Loop regulator L l t for f tension control of textile machines. Regulating prob: to synchronize the one side of loop to the other side side, to maintain the constant loop. How it works?

Process control systems applies to large section of industries Usually involves the manipulation of a variety of process variables in order to achieve automatic control. Number of variables depends p on the product p that is being g manufactured. Some of the variables can be

Pressure Temperature Flow Level Conductivity Weight

Variation in one variable can cause affect on other as well well.


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Industrial Process Controllers

1 Two position control 1.


Industrial Process Control Modes; ;


Two Position Controller Proportional Controller Integral Controller Differential Controller PI Controller PD Controller PID Controller PID-Controller

oldest strategy gy for control use of a switch ON/Off control discontinuous form of control action also known as two position controller. primitive, cheap and effective method of control if a fairly f i l large l fluctuation fl t ti of f the th process variable i bl is i acceptable. A perfect ON/Off controller is

Purpose of control is to hold the measured variable output from a process within set limits

ON when the measurement is below the setpoint and the manipulated variable is at its maximum value, OFF when measurement is above the setpoint and the MV is a minimum.
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Room heating system with on/off control


(74oF = 24oC) ( )

On/off controllers usually have inertia that introduces


What is control var? Set point ? What does the waveforms explain?

Overswings Delays or lag times before the variable attains the reference level again.

Why ?

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2 Differential action 2.

Differential or delayed y ON/OFF action Simple ON/OFF action with additional hysteresis or a dead-band built in. set reference 75, switching points are delayed by 3 3F F. OFF @ 78F On @ 72 72F F hysteresis of 6F. There is, of course, still some inertia.

Hence, the room temperature will go from about 70F to about 80F.

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